Shipping container

ABSTRACT

A shipping container that includes a frame having a plurality of longitudinal members and a plurality of side members connecting the longitudinal members, and an inner storage area. At least one non-rigid elastic panel is disposed between the plurality of longitudinal members and the side members such that an outer surface of the elastic panel is exposed, and an inner surface of the elastic panel defines a portion of the inner storage area, whereby the elastic panel allows the inner storage area to enlarge to an expanded position.

RELATED APPLICATION

This application claims benefit under 35 U.S.C. § 119 to U.S. Provisional Patent Application Ser. No. 60,675,656, filed Apr. 29, 2005.

FIELD OF THE INVENTION

The present invention relates to a shipping container. More specifically, the present invention relates to a shipping container that is expandable to accommodate larger loads, and includes both primary and second locking systems.

BACKGROUND OF THE INVENTION

Many industries rely almost exclusively on over the road trucks, rail, or barge to move materials or goods from generation sources to customer markets and/or disposal sites. Intermodal containers are used to transport materials via truck, rail and barge. Historically, the industry has utilized standard containers constructed to the International Standards Organization (ISO) specifications that are widely used by shipping and rail transportation companies.

However, those conventional containers often fail to meet the special needs of waste and other industries. Also, the conventional containers are often heavy in order to meet strength requirements. And the conventional containers often fail to provide efficient and economic transport of materials. Examples of conventional containers include U.S. Pat. No. 5,678,715 to Sjostedt et al. and U.S. Pat. No. 5,354,165 to Booher, the subject matter of each of which is herein incorporated by reference.

SUMMARY OF THE INVENTION

Accordingly, the present invention provides a shipping container that includes a frame having a plurality of longitudinal members and a plurality of side members connecting the longitudinal members, and an inner storage area. At least one non-rigid elastic panel is disposed between the plurality of longitudinal members and the side members such that an outer surface of the elastic panel is exposed, and an inner surface of the elastic panel defines a portion of the inner storage area, whereby the elastic panel allows the inner storage area to enlarge to an expanded position.

The present invention also provides a shipping container that has a frame including at least first and second end members connected by first and second side members, the first and second end members and the first and second side members define a door receiving area therebetween, and an inner storage area. A door panel is pivotally connected to the first end member and movable between open and closed positions. The door panel is received in the door receiving area such that the door panel does not extend beyond outer surfaces of the first and second end members and the first and second side members. At least one releasable locking member is supported by the frame. The locking member presses the door panel towards the inner storage area when the locking member is in a locked position.

The present invention further provides a shipping container that includes a frame having at least first and second end members connected by first and second side members. The first and second end members and the first and second side members defining a door receiving area therebetween. The frame also includes an inner storage area. A door panel is pivotally connected to the first end member and movable between open and closed positions. The door panel is received in the door receiving area. A primary door locking means is supported by the frame for locking the door panel with respect to the frame in a closed position. A secondary door locking means maintains the door panel in the closed position after the primary door locking means has been released.

The present invention also provides a shipping container including a frame with a plurality of longitudinal members, a plurality of end members, and a plurality of side members connecting the plurality of longitudinal members and the plurality of longitudinal, side, and end members are welded together to form an inner storage area. A plurality of non-rigid elastic panels are disposed between the plurality of longitudinal members and bonded thereto by adhesive. The plurality of non-rigid elastic panels allow the inner storage area to enlarge to an expanded position. A door panel is pivotally connected to one of the plurality of end members. The door panel is received in an area between the plurality of end members and two of the plurality of side members such that no portion of the door panel extends beyond outer surfaces of the plurality of end members and the two side members.

Other objects, advantages and salient features of the invention will become apparent from the following detailed description, which, taken in conjunction with the annexed drawings, discloses a preferred embodiment of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the invention and many of the attendant advantages thereof will be readily obtained as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, wherein:

FIG. 1 is a perspective view of a shipping container according to an embodiment of the present invention;

FIG. 2 is an enlarged partial perspective view of a corner joint of the shipping container illustrated in FIG. 1;

FIG. 3. is an enlarged partial perspective view of an elastic panel of the shipping container illustrated in FIG. 1;

FIG. 4 is an enlarged partial perspective view of the shipping container taken in section along line 4-4 of FIG. 1;

FIG. 5 is a side elevational view of the shipping container illustrated in FIG. 1;

FIG. 6 is an enlarged partial plan view of the shipping container taken in section along line 6-6 of FIG. 5;

FIG. 7 is an enlarged partial side elevational view of the shipping container taken in section along line 7-7 of FIG. 5;

FIG. 8 is a side elevational view of the shipping container illustrated in FIG. 1, showing a door of the shipping container;

FIG. 9 is an enlarged partial plan view of the shipping container taken in section along line 9-9 of FIG. 8;

FIG. 10 is an enlarged partial perspective view of a primary locking system of the shipping container illustrated in FIG. 8;

FIG. 11 is an enlarged partial perspective view of a tightening member of the primary locking system illustrated in FIG. 5;

FIG. 12 is a partial perspective view of the shipping container illustrated in FIG. 1, showing a portion of the door removed and showing a secondary locking system; and

FIG. 13 is an enlarged perspective view of the secondary locking system illustrated in FIG. 12.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

Referring to FIGS. 1-13, the shipping container 100 according to the present invention generally includes a frame 102 having a plurality of structural members 104 supporting a plurality of elastic panels 106 to form an open top container for transporting any type of freight or material. For example, the shipping container 100 may be used to transport goods, recycled products, forest and landscaping materials, municipal solid waste, and the like. The shipping container 100 may be any size appropriate for shipping. A door 110 is hinged inside of the structural members 104 at an end of the frame 102 providing access to an inner storage area 112 of the container 100. Because of the elasticity of the panels 106 and the way the structural members 104 and the panels 106 are bonded together, such as welding and adhesive, the shipping container 100 is light weight with higher structural stability and strength, and expands to accommodate larger loads. The design of the door 110 and its location inside of the structural members 104 provides an improved water tight seal.

As seen in FIG. 1, the frame 102 includes the plurality of structural members 104 joined by a plurality of corner joints. Specifically, the structural members 104 include first and second lower horizontal longitudinal members 120 and 122, first and second upper horizontal longitudinal members 124 and 126, and first, second, third and fourth vertical side members 128, 130, 132, and 134 connecting the lower and upper horizontal members. First and second front end members 136 and 138 extend between the first and second upper horizontal members 124 and 126 and between the first and second lower horizontal members 120 and 122, respectively. Similarly, first and second rear end members 140 and 142 extend between the upper horizontal members 124 and 126 and between the lower horizontal members 120 and 122, respectively.

Front corner joints 150 join the terminal ends of the structural members 104 together at the front of the frame 102, and rear corner joints 152 join the terminal ends of the structural members 104 together at the rear of the frame 102. For example, as seen in FIG. 2, each of first upper horizontal member 124, first vertical members 128, and first front end member 136 are bonded to the corner joint 150 by any known attachment, such as welding. Corner joints 150 and 152 may be conventional ISO blocks or lifting members.

The structural members 104 generally form the corners of the container 100. In addition to structural members 104, intermediate structural members 160 may be provided between the plurality of elastic panels 106. The intermediate structural members 160 are substantially similar to structural members 104, except that they are smaller. For example, the structural members 104 may 4 inches×6 inches, and the intermediate members 160 may be 2 inches by 4 inches. The structural members 104 and intermediate members 160 are preferably formed of a substantially rigid material, such as steel or the like. The structural members 104 and the intermediate members 160 may form channels, as seen in FIGS. 4 and 9, to reduce the weight of the container 100.

The plurality of elastic panels 106 are supported by the structural members 104 to form the container 100 and the inner storage area 112. Each side of each elastic panel 106 is bonded to either a structural member 104 or an intermediate member 160. For example, on one side of the container 100, a set of three of elastic panels 170, 172 and 174 of panels 106 may be provided that are disposed between the first lower and upper horizontal members 120 and 124 and the first and second vertical members 128 and 130, with two intermediate members 160 disposed between panels 170 and 172 and between panels 172 and 174, respectively. Similarly, on the other side of the container 100, another set of three elastic panels 176, 178 and 180 may be disposed between the second lower and upper horizontal members 122 and 126 and between the third and fourth vertical members 132 and 134, with two of the intermediate members 160 disposed between the panels 176 and 178 and the panels 178 and 180. Although sets of three elastic panels 106 are shown for each longitudinal side of the container 100, any number of panels 106 can be used including a single one-piece panel.

A rear elastic panel 182 may be disposed between the second and fourth vertical members 130 and 134 and between the rear end members 140 and 142. Opposite the rear panel 182, a door elastic panel 184 is disposed between the first and third vertical members 128 and 132 and the front end members 136 and 138 to form the door 110. One or more bottom elastic panels 186 (FIG. 7) may be disposed between the first and second horizontal members 120 and 122 and between the front end members 138 and the rear end member 142.

As seen in FIG. 1, the inner surfaces of the panels 106 define the inner storage area 112, and the outer surfaces of the elastic panels 106 are exposed, that is no shell or outer layer is disposed over the elastic panels 106. Because the panels 106 are elastic, they may enlarge to an expanded position to accommodate larger loads, and once the container is emptied, the elastic panels 106 will return to their original position. The elastic material of panels 106 is also lighter in weight than traditional materials used to form conventional shipping materials, such as steel panels, while also having high strength, toughness, and durability. The elastic material of panels 106 may be a single material or a composite. Preferably, the panels 106 are formed of a fiber reinforced polymer and filled with foam. For example, the panels 106 may be TRANSONITE® panels, available Martin Marietta Materials, which are light weight, high strength, extremely durable composite panels which includes two outer fiber reinforced polymer face sheets 302 sandwiching a foam core 306, as seen in FIG. 3. The foam 306 may include fiber posts 308 between face sheets 302 that provide reinforcement for compression. Although it is preferable that all of the panels 106 be formed of an elastic material, some of the panels may be formed of other materials. For example, the bottom panel 186 may be formed of a more rigid material, such as steel or a composite of steel and a layer of fiber reinforced polymer, to provide additional strength to the bottom of the container 100.

As seen in FIGS. 4, 6, and 9, the elastic panels 106 are preferably bonded to the structural members using a plurality of angled panel supports 400. A panel support 400 is provided along each outside edge of each elastic panel 106 to couple the panels to the structural members. For example, as seen in FIG. 4, the panel support 400 includes first and second perpendicular sections 402 and 404 that extends the length of the first upper horizontal member 124. The first section 402 is bonded to an inner surface of the upper horizontal member 124, and the second 404 is bonded to the outer surface of the elastic panels 106 (FIG. 4 showing a representative panel 170). Similarly, as seen in FIG. 9, another panel support 400 extends the height of first vertical member 128. The first section 402 of the panel support 400 is bonded to a rear surface of member 128 and the second section 404 is bonded to the outside surface of the elastic panel 106 (FIG. 9 showing representative panel 170). Likewise, two panel supports 400 may be used with the intermediate members 160 to bond the elastic panels 106 thereto. For example, as seen in FIG. 6, the first sections 402 of each panel support are bonded to the outer side surfaces of the intermediate member 160 and their second sections 404 are bonded to the outer surfaces of the adjacent elastic panels 106 (FIG. 6 showing representative panels 170 and 172). A structural tee 600 may be provided between the adjacent panels 106 to couple the end edges 602 and 604 of the panels 106 together, such as by adhesive.

It is preferable that the first sections 402 of the panel supports 400 be bonded to the structural members by welding to provide a solid bond, and that their second sections 404 be bonded to the elastic panels 106 by adhesive to provide some flexibility. That flexibility allows to panels 106 to expand while maintaining the integrity of the bond between the panels 106 and the panel supports 400. Although use of the panel supports 400 are preferred because they provide a greater surface area for bonding, the elastic panels 106 may be bonded directly to the structural members 104 or the intermediate members 160 using an adhesive. Although adhesive is the preferred way of bonding the panels to the support members, any known attachment may be used, such as fasteners, screws or the like.

The door 110 located inside of the structural members 104 at the front of the container 100. Specifically, the front vertical members 128 and 132 and the front end members 136 and 138 define a door receiving area that receives the door 110, so that no portion extends beyond the front surfaces of members 128, 132, 136, and 138. As seen in FIG. 9, the door 110 is almost flush with or slightly inset from the front surface 920 of the vertical member 128.

The door 110 is formed of the door panel 184 and may include a plurality of strength ribs 802 disposed transverse to the panel 184 and first and second peripheral strength ribs 804 and 806 disposed along the outer side edges of the panel 184, as seen in FIG. 8. A plurality of hinges 812 couple the door panel 184 to the first front end member 138 allowing the door to pivot between open and closed positions.

As seen in FIGS. 5 and 8, a primary locking assembly 500 is provided to lock the door 110 in a closed position, and generally includes a plurality of locking members 502 and a plurality of tightening members 504 to tighten the locking members 502. Two primary locking assemblies 500 may be provided with one located on each side of the container 100 (FIG. 5 showing one of the locking assemblies 500 on one side of the container 500). Each locking member 502 is generally L-shaped with a long leg 506 (FIG. 5) and a short leg 810 (FIG. 8). Each long leg 506 of each locking member 502 extends through a respective slot 820 provided in the vertical members 128 and 132 at the front of the container 100. As seen in FIG. 5, the ends of each long leg 506 of the locking members 502 are exposed and coupled to a tightening member 504 via a chain 510 at the side of the container. The tightening member 504 may be coupled to one of the structural members, such as one of the intermediate structural members 160. As seen in FIG. 11, each tightening member 504 uses a conventional mechanism, such as load binder, for tightening the chain 510.

Each short leg 810 of the locking members 502 engages the front surface of the door panel 184. More specifically, the short legs 810 abut the peripheral strength members 804 and 806 of the door 110. When the tightening members 504 are actuated, the locking members 502 are pulled back by the chains 510 so that the short legs 810 of the locking members 502 abut the front surface of the door 110 and pressed it towards the inner storage area 112 of the container 100 to lock the door in a closed position. To maintain a water tight seal, a door stop 900 is provided that is bonded to the inner surfaces of the front vertical members 128 and 132 and the lower front end member 138. A gasket 902 is bonded to a front surface of the door stop 900, so that the gasket 902 is sandwiched between the door stop 900 and the rear surface 904 of the door panel 184. When the locking members 502 are tightened, their short legs 804 press against the front surface of the door panel 184 to force the door 110 toward the inner storage area 112, thereby compressing the gasket 902. The door 110 being received inside of the front vertical members 128 and 132 and the end members 136 and 138 combined with the compression of the gasket 902 provides a water tight seal. The gasket 902 may be any compressible material such as neoprene, silicon, or the like.

To release the primary locking assembly 500, the tightening members 504 are actuated to release the tension in the chains 510, thereby allowing the locking members 502 to be removed from the slots 820 in the vertical members 128 and 132 and rotated so that the door panel 184 can be pivoted upwardly to an open position. Four locking members 502 are illustrated, however, any number of locking members 502 can with used with corresponding tightening members 504, including a single locking member 502 and a single tightening member 504. Although primary locking assembly 500, as described above is preferred, any known locking system can be used, such as chaining the door closed, or the like.

As seen in FIGS. 12 and 13, a secondary locking assembly 1210 supported at the bottom of the container 100 maintains the door 110 in the closed position even after the primary locking system 500 is released. The secondary locking assembly includes a pivotable member, such as a main bar 1310, pivotally coupled to the bottom panel 186 of the container 100 by a first pin 1312 and supported by a cross rail 1315. One end 1314 of the main bar 1310 is coupled to a pull cord 1316 that extends to the side of the container 100, as seen in FIG. 12. A biasing member 1322, such as a coil spring, that is coupled to the end 1314 of the bar 1310 and the cross rail 1315 to return the bar 1310 to a locked position after the pull cord 1316 has been released. The opposite end of the main bar 1310 includes a hook portion 1318 for engaging a second pin 1320 of the door when the door is closed. Accordingly, when the primary locking system 500 is released, the secondary locking assembly 1210 acts as a safety by maintaining the door 110 in the closed position incase the container 100 is overloaded. Specifically, the hook portion 1318 of the main bar 1310 maintains engagement with the pin 1320 of the door 110. The operator may then move to the side of the container to pull the pull cord 1316 that extends through member 120, thereby pivoting the main bar 1310 and the hook portion 1318 out of engagement of the door pin 1320, to release the door 110. Biasing member 1322 then returns the main bar 1310 to its locked position after release of the pull cord 1316. Although it is preferred that the pull chord 1316 extend to the side of the container 100, the pull chord may extend to the front. While a particular embodiment has been chosen to illustrate the invention, it will be understood by those skilled in the art that various changes and modifications can be made therein without departing from the scope of the invention as defined in the appended claims. For example, although the container 100 is illustrated as having an open top, a cover may be provided with the container 100. The cover may be formed of additional elastic panels 106, or a soft and durable sheet or panel Although various elements of the invention are referred to as front, rear, upper, or lower, horizontal, or vertical, it will be understood by those skilled in the art that those elements are not limited to front, rear, upper, lower, horizontal, or vertical, and are merely used to facilitate description of the invention. 

1. A shipping container, comprising of: a frame including a plurality of longitudinal members and a plurality of side members connecting said longitudinal members, and an inner storage area; at least one non-rigid elastic panel disposed between said plurality of longitudinal members and said side members such that an outer surface of said elastic panel is exposed, and an inner surface of said elastic panel defines a portion of said inner storage area, whereby said elastic panel allows said inner storage area to enlarge to an expanded position.
 2. A shipping container according to claim 1, wherein said elastic panel is bonded to said longitudinal members by adhesive.
 3. A shipping container according to claim 1, further comprising at least one panel support bonded to one of said plurality of longitudinal members; and said elastic panel being bonded to said panel support.
 4. A shipping container according to claim 3, wherein said panel support including first and second perpendicular sections, said first section being welded to said one of said plurality of longitudinal members, and said second section being bonded to said elastic panel by adhesive.
 5. A shipping container according to claim 1, further comprising a plurality of elastic panels disposed between said longitudinal members, outer surfaces of said plurality of elastic panels being exposed, and inner surfaces of said plurality of elastic panels forming portions of said inner storage area.
 6. A shipping container according to claim 1, wherein said elastic panel is formed of a fiber reinforced polymer.
 7. A shipping container according to claim 6, wherein said elastic panel includes a foam core.
 8. A shipping container according to claim 1, wherein said longitudinal members and said side members are substantially rigid.
 9. A shipping container according to claim 1, wherein said plurality of longitudinal members are welded to said plurality of side members; and said elastic panel are bonded to said plurality of longitudinal members and at least one of said plurality of side members by adhesive.
 10. A shipping container, comprising of: a frame including at least first and second end members connected by first and second side members, said first and second end members and said first and second side members defining a door receiving area therebetween, and an inner storage area; a door panel pivotally connected to said first end member and movable between open and closed positions, said door panel being received in said door receiving area such that said door panel does not extend beyond outer surfaces of said first and second end members and said first and second side members; and at least one releasable locking member supported by said frame, said locking member pressing said door panel towards said inner storage area when said locking member is in a locked position.
 11. A shipping container according to claim 10, further comprising a door stop extending along inner surfaces of said first and second side members and along said second end member; and a gasket disposed between said door stop and said door panel such that said door panel compresses said gasket when in the closed position.
 12. A shipping container according to claim 10, wherein said locking member is substantially L-shaped having one leg coupled to a tightening member and another leg adapted to abut the door panel.
 13. A shipping container according to claim 12, wherein said one leg of said locking member extends through a slot in one of said first and second side members.
 14. A shipping container according to claim 10, wherein said door panel is formed of an elastic material.
 15. A shipping container according to claim 10, further comprising a plurality of longitudinal members coupled to said first and second side members; and at least one elastic panel support between said first side member and one of said longitudinal members, and between said second side member and one of said longitudinal members, said elastic panels allowing said inner storage area to enlarge to an expanded position.
 16. A shipping container, comprising of: a frame including at least first and second end members connected by first and second side members, said first and second end members and said first and second side members defining a door receiving area therebetween, and an inner storage area; a door panel pivotally connected to said first end member and movable between open and closed positions, said door panel being received in said door receiving area; a primary door locking means supported by said frame for locking said door panel with respect to said frame in a closed position; and a secondary door locking means for maintaining said door panel in the closed position after said primary door locking means has been released.
 17. A shipping container according to claim 16, wherein said primary door locking means includes at least one locking member adapted to engage said door panel, and said locking member being coupled to a tightening member.
 18. A shipping container according to claim 17, wherein said locking member includes first and second legs, said first leg extends through a slot in said first side member and said second leg abuts said door panel when said door panel is in the closed position.
 19. A shipping container according to claim 16, wherein said secondary door locking means includes a pivotable member with a hook portion at one end thereof adapted to engage a portion of said door panel and a pull cord at the other end thereof for releasing the hook portion.
 20. A shipping container according to claim 19, wherein said pivotable member is a bar that includes a central pivot pin; and said hook portion of said bar engages a pin of said door panel.
 21. A shipping container according to claim 16, wherein said door panel is formed of an elastic material.
 22. A shipping container, comprising of: a frame including a plurality of longitudinal members, a plurality of end members, and a plurality of side members connecting the plurality of longitudinal members and the plurality of longitudinal, side, and end members being welded together to form an inner storage area; a plurality of non-rigid elastic panels disposed between said plurality of longitudinal members and bonded thereto by adhesive, said plurality of non-rigid elastic panels allowing said inner storage area to enlarge to an expanded position; and a door panel pivotally connected to one of said plurality of end members, said door panel being received in an area between said plurality of end members and two of said plurality of side members such that no portion of said door panel extends beyond outer surfaces of said plurality of end members and said two side members. 